Packaging method and apparatus



Jan. 28, 1964 A. w. KINNEY 3,119,213

PACKAGING METHOD AND APPARATUS Filed June 13, 1961 2 Sheets-Sheet 1 INVENTOR.

(Z/WWW United States Patent 3,119,213 PACKAGHNG METHQD AND APPARATUS Aifred William Kinney, Washington, Ni, assrgnor to American Can Qompany, New York, N.Y., a corporation of New Jersey Filed June 13, 19:31, Ser. No. 116,837 9 Claims. (Cl. 53-26) This invention relates to a method of packaging of articles and to an apparatus for forming individual articles into a company and inserting that company in a carton.

It has been found that names and terms commonly used in military maneuvers lend themselves for a clear and concise description and understanding of the present invention. Therefore, these terms, as hereafter defined are being used to enable others to understand more clearly and duplicate this invention. The term, individual, as used herein, means any single object or item which is to be packaged or inserted in a carton or container and includes, but is not limited to, such a specific item as a cup containing ice-cream, food or other commodity. The term, squad is used to identify a grouping of a preselected quantity or number of those individuals. In the present example, hereafter described and as illustrated in the drawings, a squad consists of three individuals. The term, platoon is used to identify a grouping of a pre-selected quantity or number of squads. In the present example, as described hereafter and as illustrated in the drawings, a platoon consists of two squads. The term, company is used to identify a grouping of a pie-selected quantity or number of those platoons. In the present example, as hereafter described and as illustrated in the drawings, a company consists of two platoons.

One of the objects of the present invention is to provide a method of forming individuals into a company and inserting that company in a carton.

Another object of the present invention is to provide an apparatus operative to feed individuals in a column of ones, count the individuals, form the individuals into squads, form the squads into platoons, form the platoons into companies and insert the companies into cartons.

Numerous other objects and advantages of the invention will be apparent as it is better understood from the following description which, taken in connection with the accompanying drawings, discloses a preferred embodiment thereof.

FlGURES l, 2, 3, 4 and 5 are schematic fragmentary views illustrated in perspective and showing the position of individuals at various steps during the method of forming individuals into a company and inserting that company in a carton.

FIGURE 6 is a schematic illustrated in perspective of apparatus operative in accordance with the method of FIGS. 1 to 5 inclusive and incorporating the features of the present invention.

The method of forming individuals 10 into a company and inserting that company in a carton starts by moving the individuals it} horizontally in a column of ones, as illustrated in FIG. 1. While the individuals lit are moved horizontally in this column of ones a pro-selected quantity or number of individuals 10 is separated from the column and formed into a squad 11. In FIG. 1 the squad 11, composed of a pre-selected number of individuals It), is illustrated as being in the line of movement of the column of individuals it) but separated therefrom. Following the separation and thus the formation of the squad 11 the squad 11 is moved transversely and horizontally of the column to the position as illustrated in FIG. 2. Thereafter, another squad 12 is formed in the same manner and location that the squad 11 was formed. Upon completion of the formation of the squad 12 the squads l1 and 12 are both moved horizontally and trans- 3,1 19,213 Patented Jan. 28, 1964- bi versely of the original column of ones and jointly form a platoon l3 comprised of a pro-selected number of squads. A platoon 13 comprising squads 1 1 and 12, each of which is composed of a plurality of individuals 10, is illustrated in FIG. 3 after it has been formed by moving the squads 11 and 12 transversely and horizontally from the horizontal line of movement of the column of ones.

The next step in the method is that of forcing the platoon l3 vertically downward so that another platoon may be formed at the position just being vacated by the platoon 13. The previously mentioned steps in the method are repeated to form additional individuals in the column of ones successively into squads and to form those squads into a platoon and position the succeeding platoon vertically above the platoon 13.

After the succeeding platoon has been positioned vertically above the platoon 13 the two platoons are moved vertically downward simultaneously and together and thereby combined into a company 14- illustrated in FIG. 5. The forcing of the succeeding platoon downwardly causes movement of both platoons because they are now resting one on top of the other. At this stage of the method the company 14 thus comprises two platoons arranged in layers, one over theother, with each platoon comprised of two squads with each squad comprised of three individuals. The next step in the method is to move the company 14 horizontally into an awaiting carton 1'5.

In accordance with the method as above described an individual it has thus moved through the following paths consecutively. First, it has moved in a single-file horizontal squad forming path; secondly, in a platoon-forming horizontal path normal or transverse to the squad-forming path; thirdly in a vertically downward company-forming path; and fourthly, in a horizontal carton insertion path in which the company is inserted in a carton.

Apparatus Apparatus operative in accordance with the above described method to package individuals or items in a carton is schematically illustrated in FIG. 6. The operative parts of the apparatus have been illustrated perspectively, and the machine housings, frameworks and other Wellknown supporting structures as are commonly used in machinery to support those operative parts in operative and interassociated relationship with each other have been omitted so that the invention may be more easily understood. In addition, and for purposes of easy understanding, the various operating parts of the apparatus have been given titles or names corresponding to their operative function in carrying out the above-described method. Thus, the individuals it are fed horizontally in a column of ones by a feeder 2%, for example, a common conveyor belt which moves them in the column of ones in the direction of the horizontal arrow 21. The individuals 10 are separated from the column in pre-selected quantities and formed into squads While disposed on feeder 20 by means of an individual mover 2.2 and a counter device 23 arranged one on each of the opposite sides of feeder 2i) for en agement with the individuals 1%. Movement of the individuals it in the direction of horizontal arrow 21 is controlled by individual mover 22 and ultimately stopped in the squad position by a suitable stop 24 extending across feeder 2i). The squad 11 is moved transversely of and horizontally from feeder or conveyor belt 20 and in the direction of arrow 25 in FIG. 6 by a squad mover 27.

The apparatus further includes a grid 28 aligned in juxtaposed relationship with conveyor belt 20 to receive the squads as they are moved in the horizontal direction of arrow 25 by 27. After a platoon has been formed on grid 28 it is forced vertically downward and through grid 2.8 and on to a platform elevator 29 by a platoon mover 30. The apparatus further includes a carton support 31 arranged to support a carton in receiving position such that it is juxtaposed next adjacent to elevator 29 when elevator 29 is supporting a company 14 about to be inserted in the carton 15. The company 14 is moved in the horizontal direction of an arrow 32 from elevator 29 and into carton 15 by a company mover 33.

Apparatus Details Individual mover 22 comprises a plurality of individual engager members 22a extending radially horizontally outwardly from and at equidistant points about a hub 22b. The engager members 220 are revolved by a suitable driving mechanism 22c in such manner that they will assist movement of individuals In; in the direction of arrow 21 with sufficient force to operate counter device 23 but with that force sufficiently limited to prevent damaging of individuals 10.

Counter device 23 comprises a plurality of individual counter spokes 23a extending horizontally outwardly radially from and at equidistant points about a hub 23b. The counter spokes 23a are revolved by individuals 10 being pushed thereagainst by engager members 22a as they are moved in the direction of horizontal arrow 21. The counter device 23 further includes a counter pick-off device 23c operated by movement of counter spokes 23a and hub 23b. The counter pick-off device 230 initiates action of squad mover 27 when a squad 11 has been counted out and separated from the column of ones in a manner to be described later.

Squad mover 27 comprises a squad bar 27a operatively moved in the direction of arrow 25 by means of a linear actuator 27b. If desired, squad bar 27a may be provided at the end thereof nearest individual mover 22 with a gate 27c. As best illustrated in FIG. 3, gate 271: extends across conveyor belt 2t) when squad bar 27a is moved or otherwise extended across conveyor belt 29 to push a squad 11 therefrom so as to prevent any individuals which may have passed through individual mover 22 and counter device 23 from being moved in behind squad bar 27a. Grid 28 comprises a shelf 28a and a plurality of spaced grid rods 28b. The shelf 28a is positioned horizontally in the plane of feeder to receive squads directly therefrom and is also directly beneath the incoming ends of grid rods 2%!) so as to assure that all squads being moved from conveyor belt 20 on to grid 28 are correctly positioned and fully supported by the grid rods 28b. The grid rods 23b are spaced apart a distance less than the upper cross dimension of an individual 10 so that the individuals 10 will hang between adjacent grid rods 28b.

Naturally, the grid 28 and the individuals 10 must have operative inherent characteristics normally holding the individuals 10 with cross dimensions greater than the spacing between adjacent grid rods 23b and temporarily rendering the grid rods 28b spaced apart a distance greater than the cross dimension of the individuals so as to allow the individuals in platoon 13 to be forced vertically downward through the grid 28. In the specific example wherein the individuals 16 are in the form of paper cups containing ice-cream or the like the cups are sufficiently deformable so that they may be forced downwardly through the grid 28 and will immediately regain their original shape after having passed between the grid rods 28b. It is understood that if individuals which are not deformable are to be packaged, the grid rods may be made flexible so that they will move or deform to allow individuals to be forced therethrough.

Elevator 29 comprises a platoon supporting platform 29a mounted on the upper end of a vertically movable post 29b continuously urged in a vertically upward direction by a suitable urger 29c. Elevator post 29b is provided with a plurality of notches, for example, notch 29d, arranged at equally-spaced intervals therealong and engageable by a dog 29a which may be withdrawn therefrom by a linear actuator 29f. The notches 29d are spaced apart a distance at least equal to the vertical height of an individual it) and equal to the distance in which platoon supporting platform 29a is to be forced downwardly for each layer of platoons 13 as it is stacked on top of a prior layer of platoons 13 on platoon supporting platform 29a during the forming of a company 14. After each complete company 14 has been formed on platoon supporting platform 29a and removed therefrom, urger 29c moves platoon supporting platform 29a in a vertically upward direction by withdrawing dog 29:: from notches 29d.

Platoon mover 36 comprises a plurality of platoon bars 30a supported by a linear actuator 15%. These platoon bars 33a are arranged parallel with grid rods 23b and aligned to pass therebetween while forcing a squad 11 vertically downward through grid 28 and on to platoon supporting platform 29a.

Carton support 31 comprises a shelf 31:: cantileverly supported on a hinge shaft 31b having a notch 31c engageable by a dog 31d. Shelf 31a is aligned with platoon supporting latform 29a when dog 31d is in potch 31c and during the transfer of a company from platoon supporting platform 29a into a carton 15 carried by platoon shelf 31a. The dog 31d is moved outwardly from notch 31c by means of a linear actuator 31c.

Company mover 33 comprises a company pusher bar 33a and a linear actuator 33b connected thereto. Linear actuator 33!) moves pusher bar 33a in the horizontal direction of the arrow 32.

The linear actuators 27b, 33b, 30b, 29f and 31e may be of any suitable electrical, hydraulic, pneumatic or mechanical type actuators capable of moving their respective parts in the respective directions as hereinbefore described. Inasmuch as linear actuators, their operation and the control of their energization are well known in the art, they are schematically illustrated in FIG. 6 as all being connected to a common energy control 40 by their respective connections 27k, 33k, 30k, 29k and 31k. In addition, driving mechanism 220 may also be energized from this same energy control 40 through the connection 22k. Timed sequence of energization of the linear actuators and limiting movement control thereof is also schematically illustrated by means of position responsive devices operatively interconnected with energy control 40.

The position of squad bar 27a operates position responsive devices 27t1, 27:2 and 27t3 which are interconected with energy control 40 through position responsive device connector 27t to interassociate the energization of the linear actuators with the position of squad bar 27a.

The position of platoon mover 30a operates position responsive devices 30d and 30t2 which are interconnected with energy control 40 through position responsive device connector 30t to interassociate the energization of the linear actuators with the position of platoon mover 30a.

The position of company mover 33a operates position responsive devices 3311 and 33t2 which are interconnected with energy control 40 through position responsive device connector 33t to interassociate the energization of the linear actuators with the position of company mover 33a.

Counter pick-off device 23c is connected to energy control 40 by a connection 23t and a position responsive device 1511, responsive to the position of a carton 15 on shelf 31a, is also connected to energy control 40 by a connection 15!.

The apparatus described and illustrated herein operates in accordance with the method to form individuals into a company and insert that company in a carton. In accordance with the invention the apparatus moves the individuals horizontally in a column of ones, supports a pro-selected number of individuals from the column and forms them into squads. Thereafter, the apparatus moves the squads one at a time and one after the other transversely of and horizontally from the column so as to form a preselected number of squads into a platoon. Following this, the apparatus forces the platoons vertically downward and combines a pro-selected number of platoons into a company. After a company has been formed the apparatus moves that company in a horizontal direction into an awaiting carton. The apparatus then dispenses the carton so that another carton may be positioned to receive more individuals.

It is thought that the invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction, and arrangement of parts of the apparatus mentioned herein and in the steps and their order of accomplishment of the method described herein, without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the apparatus and process hereinbefore described being merely a preferred embodiment thereof.

I claim:

1. A method of casing articles such as packages, containers and the like comprising the steps of feeding said articles in processional column-like order along a substantially horizontal path of travel, individually counting out and separating a predetermined number of the leading ones of said articles and bringing them to rest in closely grouped relation, shifting said grouped articles laterally from said path of travel onto spaced parallel support rods which yieldably engage respective wall surfaces on opposite sides of each article and suspend said articles freely therebetween, positively forcing said articles vertically downwardly to strip them from between said support rods and onto an upwardly biased elevator which descends under the force applied to said articles to a lower level which is displaced from the original elevator position by a distance at least equal to the height of said articles, temporarily locking said elevator at said lower level while shifting a succeeding group of said articles onto said support rods, repeating the foregoing sequence to group a predetermined number of said articles on said elevator tier upon tier, and shifting said tiered articles laterally from said elevator into an awaiting packing case.

2. The method of claim 1 wherein the first of said shifting steps includes a series of initial short lateral movements to shift succeeding columns of said grouped articles from said path of travel and a final long movement to shift a predetermined number of columns of said articles fully onto said support rods.

3. A method of easing articles characterized as having non-uniform cross dimensions, such as capped cartons having peripherally extending seams, taper side wall containers, and the like, comprising the steps of feeding said articles in a processional column along a substantially horizontal path of travel, counting out and se anating a predetermined number of the leading articles in said column and bringing them to rest in a closely grouped row, successively shifting each row as it is formed laterally from said path or" travel into grouped columns of predetermined number and into suspended position between spaced parallel support rods which make yieldable engagement with said articles in each of said rows beneath their maximum cross dimension, positively forcing said grouped columns simultaneously downwardly from between said support rods and onto an upwardly biased elevator which descends under the force applied to said articles to a level corresponding to their downward movement, temporarily locking said elevator at its level of descent while shifting another group of columns into position on said support rods, repeating the foregoing sequence until a predetermined number of articles have been grouped on said elevator tier upon tier, and shifting said tiered articles laterally from said elevator into an awaiting packing case 4. Apparatus for easing [articles such as packages, containers and the like comprising a conveyor for feeding said articles in processional column-like order along a 6 substantially horizontal path of travel, means for counting out and separating a predetermined number of the leading ones of said articles as they move along said path, a stop member transversely overlying said conveyor for bringing said predetermined leading articles to rest in closely grouped relation, support means laterally of said conveyor and adjacent said stop member, said support means having parallel support rods extending perpendicularly to said conveyor and being spaced apart a distance suflicient to suspend individual ones of said articles therebetween, a horizontally reciprocating pusher opposite said support means and operable transversely of said conveyor in synchronism with said counting and separating means to shift said closely grouped articles laterally from said conveyor onto said support rods, a vertically reciprocating press member disposed above said support rods and operable in synchronism with said horizontal pusher to descend and positively strip said articles from said support rods, an upwardly biased elevator disposed beneath said support rods and operable to descend with said articles thereon under the force of said press member to a level corresponding to the downward movement of said articles, lock means operable to prevent upward movement of said elevator upon retraction of said reciprocatory press member, control means operable to repeat the sequence of the foregoing elements until a predetermined number of said articles have been grouped on said elevator tier upon tier, a case supporting frame adjacent one side of said elevator at a level corresponding .to its maximum descent when said predetermined number of said articles are tiered thereon, and a second horizontally reciprocating pusher disposed opposite said case frame and operable in synchronism with said control means to shift said tiered articles laterally from said elevator directly into a packing case placed in said frame.

5. The apparatus of claim 4 wherein said support means comprises a stationary platform disposed along one side of and level with said conveyor, and said sup port rods overlie said platform a distance less than the height of said articles and extend beyond said platform a distance sufiicient to suspend a predetermined number of articles freely above said elevator to one side of said platform.

6. The apparatus of claim 4 wherein said first horizontal pusher is operative in a series of initial short strokes to shift successive columns of said articles from said conveyor as they are formed thereon and a final long stroke to shift a predetermined number of columns of said articles fully onto said support rods.

7. The apparatus of claim 4 wherein said counting and separating means comprises a driving st-ar wheel operative on one side of said conveyor to positively advance successive ones of said articles along said path in predetermined spaced relation, and a driven star wheel on the opposite side of said conveyor operable under the motion of said articles advanced therethrough by said driving star wheel to register counting impulses in said control means.

8. The apparatus of claim 4 wherein said elevator comprises a horizontal platform mounted to a column, biasing means operative to maintain a continuous up- Ward force on said column, and ratchet means associated with said column for releasably locking said platform at increments of elevation against: upward movement in synchronism with said control means.

9. Apparatus for casing articles characterized as having non-uniform cross dimensions, such as capped cartons having peripherally extending seams, tapered side wall containers, and the like, comprising a conveyor for feeding said articles in a processional column along a horizontal path of travel, means for positively separating and counting out in spaced relation predetermined number of the leading articles in said column as they move along said path, a stop member transversely overlying said conveyor for bringing said predetermined leading articles to rest in a closely grouped row, a support means to one side of said conveyor adjacent said stop member and having parallel support rods extending perpendicularly away from said conveyor a distance sufficient to accommodate a predetermined number of said rows, said rods being spaced above said conveyor a distance less than the height of the maximum cross dimension of said articles and spaced apart a distance sufiicient to yieldably suspend individual ones of said articles in said rows therebetween beneath their maximum cross dimension, a horizontally reciprocating pusher opposite said support means and operable transversely of said conveyor in synchronism with said counting and separating means to shift successive ones of said rows laterally from said conveyor onto said support rods, a vertically reciprocating press member disposed directly above said support rods and operable in synchronism with said horizontal pusher to descend and strip said rows from said support rods, an upwardly biased elevator disposed directly beneath said support rods and operable to descend with said rows of articles thereon under the force of said press member to a level corresponding to the downward movement of said articles, lock means operable to temporarily retain said elevator at successive levels against upward movement, control means operable to repeat the sequence of the foregoing elements until a predetermined number of said articles have been grouped on said elevator tier upon tier, :1 case supporting frame adjacent one side of said elevator at a level corresponding to its maximum descent when said predetermined number of articles are tiered thereon, and a second horizontally reciprocating pusher disposed opposite said case frame and operable in synchronism with said control means to shift said tiered articles laterally from said elevator directly into a packing case placed in said frame.

References Cited in the file of this patent UNITED STATES PATENTS 2,738,116 Barraclough Mar, 13, 1956 2,857,721 Ardell et al. Oct. 28, 195 2,956,384 Underwood Oct. 18. 1960 

1. A METHOD OF CASING ARTICLES SUCH AS PACKAGES, CONTAINERS AND THE LIKE COMPRISING THE STEPS OF FEEDING SAID ARTICLES IN PROCESSIONAL COLUMN-LIKE ORDER ALONG A SUBSTANTIALLY HORIZONTAL PATH OF TRAVEL, INDIVIDUALLY COUNTING OUT AND SEPARATING A PREDETERMINED NUMBER OF THE LEADING ONES OF SAID ARTICLES AND BRINGING THEM TO REST IN CLOSELY GROUPED RELATION, SHIFTING SAID GROUPED ARTICLES LATERALLY FROM SAID PATH OF TRAVEL ONTO SPACED PARALLEL SUPPORT RODS WHICH YIELDABLY ENGAGE RESPECTIVE WALL SURFACES ON OPPOSITE SIDES OF EACH ARTICLE AND SUSPEND SAID ARTICLES FREELY THEREBETWEEN, POSITIVELY FORCING SAID ARTICLES VERTICALLY DOWNWARDLY TO STRIP THEM FROM BETWEEN SAID SUPPORT RODS AND ONTO AN UPWARDLY BIASED ELEVATOR WHICH DESCENDS UNDER THE FORCE APPLIED TO SAID ARTICLES TO A LOWER LEVEL WHICH IS DISPLACED FROM THE ORIGINAL ELEVATOR POSITION BY A DISTANCE AT LEAST EQUAL TO THE HEIGHT OF SAID ARTICLES, TEMPORARILY LOCKING SAID ELEVATOR AT SAID LOWER LEVEL WHILE SHIFTING A SUCCEEDING GROUP OF SAID ARTICLES ONTO SAID SUPPORT RODS, REPEATING THE FOREGOING SEQUENCE TO GROUP A PREDETERMINED NUMBER OF SAID ARTICLES ON SAID ELEVATOR TIER UPON TIER, AND SHIFTING SAID TIERED ARTICLES LATERALLY FROM SAID ELEVATOR INTO AN AWAITING PACKING CASE. 